Transport system for fabric pieces

ABSTRACT

The fabric transport system comprises a series of fluidly communicating tubes and includes: an intake line configured to receive a fabric piece from the predetermined departure location; a main line fluidly connected at one end with the intake line; a branch line being fluidly connected at its upstream end to an intermediate portion of the main line at a junction; a vacuum source connected with the downstream end of the branch line for drawing air of sufficient quantity and velocity through the intake line, the main line, and the branch line to draw a fabric piece into the intake line and the main line; and a counterflow valve positioned on an intermediate portion of the main line downstream of the junction between the main line and the branch line. The branch line includes a deposit nozzle leading to the predetermined destination. The fabric transport system further includes means, such as an electronic controller, for actuating the counterflow valve to take its open position prior to a fabric piece passing the junction such that air is drawn into the main line and subsequently into the branch line by the vacuum source.

FIELD OF THE INVENTION

The present invention relates generally to manufacturing processes, andrelates more particularly to a textile clothing manufacturing process.

BACKGROUND OF THE INVENTION

There is significant interest in the clothing industry to reduce thecost of producing clothing while also improving clothing quality, fit,and availability. One proposal to improve the speed and quality withwhich clothing is produced is the APPAREL ON DEMAND™ clothing productionconcept developed by Textile Clothing Technology Corporation of Cary,N.C. This concept is one in which garments are custom-produced forcustomers through automated processes. The concept begins with thecustomer selecting patterns and fabrics for a particular garment at aclothing store. The customer is then electronically measured at thestore or other location. The customer's measurements are transmitted toa remote location, where fabric is accessed, custom-cut and sewn basedon the customer's fabric and pattern selections and measurements. Thefinished product is then returned to the clothing store where it isfurnished to the customer.

Clearly, one of the key elements to the aforementioned productionconcept is the factory in which the clothing is actually cut and sewn.In such a factory, because clothing is not mass-produced in the samefabric pattern, it is often more efficient to have several differentstations for producing components of a garment in different locations.For example, sleeves for different garments may be sewn in one location,lapels and buttonholes in another, and front and rear panels in a third.These components might then be combined at a separate finishing stationto produce the finished garment.

Generally, fabric for a garment, suit, or ensemble is cut from alocalized area on the same sheet of cloth to ensure precise colormatching. This presents a manufacturing difficulty if, as describedabove, the factory has multiple stations for sewing different componentsof a garment. Conventional manufacturing facilities are constructed suchthat fabric pieces from an original cloth sheet are manually removedfrom the cutting station and manually distributed to the work stations,which requires that each piece be labeled to identify how the garment isto be assembled.

In some facilities, many layers of cloth may be cut at a single cuttingstation and then transferred to different sewing stations. This methodrequires the handling of bundles of cut fabric pieces, which presentsproblems such as color matching, distribution of the bundles to remoteworkstations, and reduced garment size flexibility. Moreover, in such asystem, safeguards should be included to ensure that the fabric piecesare labelled; otherwise an operator at a sewing station mayinadvertently sew together pieces intended for different garments. Also,because the sewing of fabric pieces is performed at locations remotefrom cutting, it is important that the transportation of the fabricpieces be rapid and, in the interest of cost, accomplished with aminimum of labor.

Prior work has been completed for the transport of textile articleswithin a manufacturing facility. For example, U.S. Pat. No. 3,207,559 toPoteat et al. is directed to a textile article collection system. Thesystem is designed to receive articles, such as hosiery, from differentsources and transport them to a common collection point. The systemincludes a series of knitting machines, each of which is equipped with ablower and a delivery tube. Each delivery tube ultimately leads to amain conveyor tube, which in turn leads to a discharge tube that emptiesinto a collection container. In this system, articles are conveyed bypositive pressure applied by the blower through the delivery tube andinto the main conveyor tube; they then pass through the discharge tubeand into the container.

As another example of a system for transporting textiles betweendifferent locations, U.S. Pat. No. 3,163,470 to Brewin et al. discussesa distribution system for lightweight articles, such as textiles. Thesystem includes a central duct that feeds into a tube having ahorizontal run. In the horizontal run are several tubular T-fittingsthat lead to branch pipes. A one-way flap valve is positioned betweeneach T-fitting and each branch pipe. A series of nozzles are attached tothe horizontal run and are positioned so that each directs a blast ofair through the stem of the T-fitting and toward the valve. Inoperation, textile articles from a common source, such as an examiningpoint, are received within the central duct and proceed from therethrough the tube into the horizontal run. Only one of the nozzles isactuated; the remaining nozzles are not. Actuation of the nozzle opens avalve flap of the corresponding valve and also propels the textilearticle through the stem of the corresponding T-fitting, through thevalve, and into the pipe for further passage to its appointeddestination.

One significant shortcoming of the Brewin system is that it includes noprovision for textile articles that "overshoot" the intended branchpipe; if a textile article has sufficient momentum to travel past theproper branch pipe despite the air blast from the corresponding nozzle,there is no back-up system in place to recover the article and return itto the proper location. Thus, if an article overshoots its intendeddestination, not only is that article unlikely to be correctlydistributed, it can also block the system for subsequent articles. Asdiscussed above, inaccuracy in delivery of parts can reduce efficiencyof sewing operations significantly.

SUMMARY OF THE INVENTION

In view of the foregoing, it is an object of the present invention toprovide a system for transporting fabric pieces from a cutting table toa predetermined one of a number of different destinations quickly andeasily.

It is also an object of the present invention to provide a method foroperating such a system.

It is a further object of this invention to provide a system fortransporting fabric articles to a predetermined one of a number ofdestinations that includes a mechanism for preventing and correcting"overshooting" of fabric articles.

It is still another object of the present invention to provide a methodfor using such a fabric transport system.

These and other objects are satisfied by the present invention, whichprovides a rapid, accurate system for transporting fabric pieces from apredetermined departure location to one of a number of predetermineddestinations. The fabric transport system comprises a series of fluidlycommunicating tubes and includes: an intake line configured to receive afabric piece from the predetermined departure location; a main linefluidly connected at one end with the intake line; a branch line beingfluidly connected at its upstream end to an intermediate portion of themain line at a junction; a vacuum source connected with the downstreamend of the branch line for drawing air of sufficient quantity andvelocity through the intake line, the main line, and the branch line todraw a fabric piece into the intake line and the main line; and acounterflow valve positioned on an intermediate portion of the main linedownstream of the junction between the main line and the branch line.The branch line includes a deposit nozzle leading to the predetermineddestination. The fabric transport system further includes means, such asan electronic controller, for actuating the counterflow valve to takeits open position prior to a fabric piece passing the branch linejunction such that secondary air is drawn through the counterflow valveinto the main line and subsequently into the branch line by the vacuumsource. As a result, a fabric piece traveling in the main line is urgedby the secondary air to be shunted into the branch line (andsubsequently into the deposit nozzle and to the predetermineddestination) from the main line even if its momentum causes it to passthe branch line junction initially.

In a preferred embodiment, the fabric transport system of the presentinvention includes a fabric cutting table for supporting a fabric sheet,a knife, laser, or other cutting means for cutting a fabric sheet intoone or more fabric pieces, and a table or other support means forsupporting the fabric pieces in respective departure positions.Preferably, the support, or unloading, table is integrated with thecutting table and cutting means such that the fabric pieces remain inthe same pattern on the unloading table as when they were cut. Also, itis preferred that the system include multiple branch lines that arefluidly connected with the main line.

In another embodiment, the fabric transport system includes at least asecond branch line that intersects with the main line and that leads toa second predetermined destination. Preferably, the main line includes asecond counterflow valve positioned downstream of the intersectionbetween the second branch line and the main line to assist a fabricpiece into the second branch line and subsequently to the secondpredetermined destination.

Another aspect of the present invention is a branch line of a fabrictransport system that includes an upstream conduit, a downstreamconduit, a deposit nozzle, and a bifurcating section having a lumen. Theupstream conduit is connected to the main line and to the depositnozzle. The deposit nozzle has a downstream outlet end that resideswithin the lumen of the bifurcating section and leads to a predetermineddestination. The downstream conduit is fluidly connected to thebifurcating section and to a vacuum source. The downstream conduit isconnected with the bifurcating section at a junction positioned adjacentan intermediate portion of the deposit nozzle. As such, air exiting thedeposit nozzle must reverse its direction to flow into the downstreamconduit. In this configuration, a fabric piece exiting the depositnozzle has sufficient momentum to continue in the direction it wastraveling and therefore reach the predetermined destination; it does notreverse its direction and follow the air flow into the downstreamconduit. As a result, the fabric piece is simply deposited into areceiving container, such as a receiving tube, at the predetermineddestination. Preferably, the downstream end of the deposit nozzle isnarrower than the upstream end in order to accelerate the exiting fabricpiece as it travels therethrough.

The present invention is described in greater detail hereinbelow withreference to the following drawings.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a plan view of an exemplary fabric transport system of thepresent invention.

FIG. 2 is an enlarged perspective view of a branch line and receivingstation of FIG. 1.

FIG. 3 is an enlarged end view of a receiving station of FIG. 2 with theexit door in its closed position.

FIG. 4 is a partial section view taken along lines 4--4 of FIG. 2showing the diverging paths of air and fabric within the branch line.

FIG. 5 is a top section view of a receiving station taken along lines7--7 of FIG. 3 showing a fabric piece received in a receiving tube.

FIG. 6 is a top section view of the receiving station of FIG. 5 takenalong lines 7--7 of FIG. 3 rotated slightly clockwise with the positionof the bifurcating section represented in phantom line.

FIG. 7 is a top section view taken along lines 7--7 of FIG. 3 showingthe receiving station rotated 90° from its position in FIG. 5 such thata second receiving tube receives a fabric piece and the first receivingtube is in position to be unloaded of its fabric piece.

FIG. 8 is a schematic illustration of an exemplary controller employedwith the fabric transport system of the present invention to controlcutting, unloading, and transport operations.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The present invention will now be described more fully hereinafter. Thisinvention may, however, be embodied in many different forms and shouldnot be construed as limited to the embodiment set forth herein; rather,this embodiment is provided so that this disclosure will be thorough andcomplete, and will fully convey the scope of the invention to thoseskilled in the art.

As noted above, the present invention relates to an apparatus and methodfor transporting fabric pieces from a departure point, such as a cuttingor unloading table, to a predetermined one of multiple destinations. Thetransport system includes a series of fluidly interconnected tubes orpipes (also referred to as lines, conduits, and the like), with thefabric pieces being conveyed through certain of these pipes. In thedescription of the present invention that follows, certain terms areemployed to refer to the positional relationship of some structures orcomponents relative to other structures. As used herein, the term"downstream" and derivatives thereof refer to the general directionfabric pieces and air travel as they move within the pipes of thesystem; this term is often used in manufacturing environments toindicate that certain material being acted upon has proceeded farther inthe manufacturing process than other material. Conversely, the term"upstream" and derivatives thereof refer to the direction opposite thedownstream direction. Together, the forward and rearward directionscomprise the "longitudinal" dimension. As used herein, the terms"outer", "outward", "lateral", and derivatives thereof refer to thedirection defined by a vector originating at the longitudinal axis of agiven structure and extending perpendicularly thereto. Conversely, theterms "inner", "inward", and derivatives thereof refer to the directionopposite that of the outward direction. Together, the inward and outwarddirections comprise the "transverse" dimension. It should be noted that,relative to an absolute x-y-z coordinate axis system, these directionsshift as the fabric pieces are conveyed between different portions ofthe piping system due to the layout of equipment on the plant floor.When they occur, the downstream direction is redefined with reference tothe direction of air flow. It is to be understood that, when theseshifts in the downstream direction occur, the other directions definedabove shift similarly to retain their relative orientation with thedownstream direction.

Turning now to the Figures, an exemplary fabric transport system,designated broadly at 10, is illustrated schematically in FIG. 1. Thefabric transport system 10 comprises generally a cutting station 11, apiping system 30, three vacuum sources 80, and a series of receivingstations 90. Each of these general components is described hereinbelowin greater detail.

The cutting station 11 comprises a cutting apparatus 14, which cutsindividual fabric pieces 15 from a sheet of fabric unrolled from atransversely-disposed fabric roll 12. The cutting apparatus 14 can beany cutting apparatus known in this art to cut fabric pieces 15according to a defined pattern, such as those employing a knife, laser,or other cutting device. It is preferred that the cutting apparatus 14be electrically connected to a controller 17 (FIG. 8), microprocessor orother control system that is operably coupled with the cutting blade orlaser and which has a receiving module that receives customerinformation and selects the proper pattern size based on a customer'smeasurements at a retail store or other location.

As described in greater detail hereinbelow, the controller 17 iselectrically connected to position sensors, valves, and other componentsof the fabric transport system 10. Those skilled in this art willappreciate that the controller 17 can be configured in numerous wayswith these components. Also, it should be understood that, whencomponents are described herein as being "operatively coupled," thesecomponents are connected through the controller 17 such that an eventoccurring at, within, or to one component signals the controller toinitiate an event with the operatively coupled component. This couplingcan be instantaneous within the controller 17, or the signal from thecontroller 17 can be delayed for a predetermined time period as desired.

After the fabric is cut from the fabric roll 12, the fabric pieces 15are conveyed to a horizontally-disposed unloading table 16 (FIG. 1).Illustratively and preferably, the fabric pieces 15 remain in the samerelative positions as they take when they are cut at the cutting station11. A gantry unit 18, which includes two longitudinally-extendingchannels 20 and a cross-member 22 that extends transversely across thepresentation surface of the unloading table 16, is positioned above theunloading table 16. The cross-member 22 is mounted to the channels 20such that it can translate longitudinally over the fabric pieces 15. Asuction head 24 is slidably mounted for traverse movement on thecross-member 22. An articulating pincher 25 or other pick-up device ispositioned on the suction head 24. The combined longitudinal movement ofthe cross-member 22 and the transverse movement of the suction head 24enables the suction head 24, and therefore the pincher 25, to be movedto virtually any position above and adjacent the fabric pieces 15resting upon the unloading table 16. Movements of the cross member 22and the suction head 24 are directed by the controller 17 (see FIG. 8)based on the desired sequence for transporting fabric pieces to specificreceiving stations 90.

Those skilled in this art will appreciate that other means for movingthe suction head 24 to desired positions above the unloading table 16,such as a pivoting member mounted overhead via a ball-and-socket joint,a telescoping pivoting arm, a robotic articulating arm, or the like, canalso be used with the present invention. Also, other pick-up devices,such as an articulating arm of a different configuration, asuction-based device, or the like, may also be suitable for the presentinvention.

The suction head 24 is connected with the piping system 30 via an intakeline 31, which includes an inlet nozzle 32 attached directly to thesuction head 24 adjacent to the pincher 25 (FIG. 2). The inlet nozzle 32leads to a flexible section 34 of the intake line 31 which hassufficient flexibility and resilience to enable the suction head 24 tomove to any desired position above the unloading table 16. The flexiblesection 34 is attached at its downstream end to a more rigid,horizontally-disposed manifold section 35 of the intake line 31, wherethe intake line 31 terminates. The size of the pipes used to form theintake line 31 and the other lines of the piping system 30 are notcritical; piping having a diameter of between about 3 and 4 inches istypically suitable for use with the present invention.

A counterflow valve 36 is connected to a downstream portion of themanifold 35. The counterflow valve 36 is electrically connected to thecontroller 17. Also, a photoelectric sensor 37 or other means fordetecting the presence of a fabric piece in the manifold 35 ispositioned at the upstream end of the manifold 35. Preferably, thephotoelectric sensor 37 is operably coupled with the counterflow valve36 through the controller 17.

As shown in FIGS. 1 and 2, three main lines 40a, 40b, 40c directly mergewith the manifold section 35, with the main lines 40b and 40c exitingthe manifold 35 upstream of the counterflow valve 36, and the main line40a exiting the manifold 35 downstream of the counterflow valve 36.Except for the locations on the manifold section 35 with which the mainlines 40a, 40b, 40c connect, the main lines 40a, 40b, 40c are generallysimilar in configuration and operation. In the interest of clarity andbrevity, only the main line 40a will be described in detail hereinbelow;those skilled in this art will understand that the discussion of themain line 40a is equally applicable to main lines 40b and 40c . Also,those skilled in this art will understand that, although the main lines40b and 40c are illustrated at having the same number of receivingstations 90 located in the same positions as those of main line 40a,these components can be varied in number and position and still beencompassed by the present invention.

Referring again to FIG. 1, just downstream of its interconnection withthe manifold section 35, the main line 40a includes a routing valve 42awhich is electrically connected with the controller 17. The routingvalve 42a, as well as the other valves described herein, can be anyknown to those skilled in this art to be moveable between open andclosed positions and thereby permit and prevent air flow. Opening andclosing of the valve 42a is controlled by the controller 17 (FIG. 8);illustratively and preferably, the controller 17 controls the opening ofthe routing valves 42a, 42b, 42c such that, at most, only one of thesevalves is in its open position at any time to prevent a fabric piecefrom entering the incorrect main line.

Just downstream of the routing valve 42a, a photoelectric sensor 43 orother means configured to detect the presence of a passing fabric pieceis positioned adjacent to the main line 40a (FIG. 1). Also, asupplementary air valve 44 is positioned slightly downstream of thesensor 43. Both the photoelectric sensor 43 and the supplementary airvalve 44 are electronically connected to the controller 17 (FIG. 8),which operably couples these components such that passage of a fabricpiece past the photoelectric sensor 43 signals the controller 17 to openthe supplementary valve 44. Similarly, the routing valve 42a is operablycoupled with the photoelectric sensor 43 so that detection thereby of apassing fabric piece 15 causes the controller 17 to signal the routingvalve 42a to close.

Continuing to move downstream along the main line 40a (FIG. 1), fourT-fittings 46, 48, 50, 52 are spaced along the expanse of the main line40a, each of which interconnects with a branch line 70. Preferably, eachT-fitting includes a sizable inner radius between its main portion andits stem to facilitate the change in direction a fabric piece 15 mustundergo to travel into the stem. A photoelectric sensor 54 is positionedjust upstream of T-fitting 48, and a counterflow valve 56 is positionedjust downstream of T-fitting 48. Both the photoelectric sensor 54 andthe counterflow valve 56 are electrically connected to the controller 17(FIG. 8). Also, just upstream of the T-fitting 52, a photoelectricsensor 58 is positioned adjacent the main line 40a, and a counterflowvalve 60 is positioned just downstream of the T-fitting 52. As describedabove for the photoelectric sensor 54 and the counterflow valve 56, boththe photoelectric sensor 58 and the counterflow valve 60 areelectrically connected to the controller 17.

FIG. 2 illustrates a branch line 70, a receiving station 90, and theinterrelationship of these components thereof with a vacuum source 80.Those skilled in this art will recognize that, although only a singlebranch line 70, receiving station 90, and vacuum source 80 are describedin detail herein, the discussion thereof is equally applicable to theother branch lines 70, vacuum sources 80, and receiving stations 90.

Referring to FIGS. 2 and 3, the branch line 70 comprises an upstreamconduit 72 having a deposit nozzle 74 on its downstream end, abifurcating section 76, and a downstream conduit 78. The deposit nozzle74 fits within the lumen of the bifurcating section 76 such that thedeposit nozzle outlet end 75 is positioned well below the stem of thebifurcating section 76. The deposit nozzle outlet end 75 is alsonarrower in cross-section then its upstream end. The stem of thebifurcating section 76 is connected with the upstream end of thedownstream conduit 78, which leads to and interconnects with a commonvacuum line 82.

A vacuum valve 79 is positioned on the downstream conduit 78 justdownstream of the bifurcating section 76. The vacuum valve 79 iselectrically connected to the controller 17 (FIG. 8) such that, if thereceiving station 90 corresponding to the branch line 70 that containsthe vacuum valve 79 is to be the destination for a fabric piece 15, thevacuum valve 79 takes an open position; otherwise, that vacuum valve 79remains closed.

As is illustrated schematically in FIG. 2, the vacuum line 82 is fluidlyinterconnected with each of the downstream conduits 78 of each of thebranch lines 70 that lead from the main line 40a. The vacuum line 82leads to a single vacuum source 80 (driven by a vacuum motor 84 shownschematically in FIG. 8), which provides suction to all the branch lines70 interconnected with the main line 40a. Those skilled in this art willappreciate that the vacuum source 80 can be any known to those skilledin this art to be capable of providing a vacuum through the pipingsystem 30 sufficient to lift a fabric piece 15 from the unloading table16 and convey it through the piping system 30 to a receiving station 90.Exemplary vacuum sources include pumps, blowers, and the like. It ispreferred that each vacuum source 80 operate continuously, althoughintermittent operation of a vacuum source that coincides with thepassage of a fabric piece 15 through the main line 40a is also suitable.For either continuous or intermittent blower operation, it is preferredthat the vacuum motor 84 be electrically connected to the controller 17and its operation be coupled to the transport of a fabric piece 15 inthe attached main line 40a. Typically, the vacuum source 80 shouldprovide between about 300 and 400 cfm of airflow to enable the fabricpieces 15 to be lifted from the unloading table 16 into the pipingsystem 30.

As seen in FIGS. 2 and 3, the receiving station 90 comprises a rotatablecarousel 92 having four vertically-oriented, cylindrical receiving tubes94. The carousel 92 is positioned beneath a stationary plate 95 that ismounted at the downstream end 75 of the deposit nozzle 74. Eachreceiving tube 94 is open at its upper end and closed via a hinged exitdoor 96 at its lower end. The exit door 96 may be manually operated ormay be connected to a remote actuator, such as a foot pedal (not shown)that can be actuated by the operator. The carousel 92 rotates about asubstantially vertical axis so that each receiving tube 94 can move to aposition beneath the longitudinal axis the deposit nozzle 74.Preferably, the receiving station 90 includes a drive motor 97 (shownschematically in FIG. 8) or other drive means for driving the carousel92 between receiving positions. The motor 97 is preferably electricallycoupled with the controller 17 so that a desired receiving tube 94 isrotated beneath the longitudinal axis of the deposit nozzle 74 toreceive a fabric piece. Also, the receiving station 90 can include aposition sensor (not shown) within the receiving tubes or in anotherlocation which is connected to the controller 17 to signal the arrivalof a fabric piece 15 therein; this signal can be operatively coupledwith the vacuum valve 79 and the supplementary air valve 44 such thatdetection of a fabric piece 15 within a receiving tube 94 causes thevacuum valve 79 to close. Further, the receiving tube 94 may alsoinclude means for assisting the fabric pieces 15 to exit the receivingtube 94, such as an air jet or plunger, to prevent inadvertent stickingor clogging by fabric pieces.

Operation of the fabric transport system 10 begins with the cuttingapparatus 14 cutting fabric pieces 15 from a fabric sheet supplied bythe fabric roll 12. The fabric pieces 15 are then conveyed to theunloading table 16. The controller 17 then signals the gantry unit 18 tomove the suction head 24 to a predetermined location generally above thefirst fabric piece 15 intended for transport. Preferably, the suctionhead 24 is moved to a location in which the pincher 25 can pickup acentral portion of a fabric piece 15.

As the suction head 24 is moving into position, the controller 17signals the routing valve 42a, 42b, 42c positioned on the main line 40a,40b, 40c which is to receive the fabric piece 15 to open. For example,if the fabric piece 15 is to be conveyed into main line 40a, the routevalve 42a opens while routing valves 42b and 42c remain closed. As aresult, the fabric piece 15 is assured of being conveyed into the mainline 40a rather than to either of main lines 40b or 40c. Also, thevacuum valve 79 on the branch line 70 that leads to the desiredreceiving station 90 is opened by the controller 17. All other vacuumvalves 79 on the other branch lines 70 on main line 40a remain closed.Consequently, the vacuum source 80 draws air through the suction head24, the intake line 31, the main line 40a, that branch line 70, and thevacuum line 82.

After the proper vacuum valve 79 and routing valve 42a have been openedand the suction head 24 has moved into position, the fabric piece 15 ispicked up by the pincher 25, moved thereby to the inlet nozzle 32, andreleased. Suction through the intake line 31 draws the fabric piece 15into the intake nozzle 32. Because the suction head 24 can move directlybetween fabric pieces 15 rather than having to move completely away fromthe unloading table 16, pick-up of subsequent fabric pieces 15 is quiteefficient and involves no wasted motion.

After the fabric piece 15 has entered the intake nozzle 32, it passesthrough the flexible tubing 34 and into the manifold 35. In sotravelling, the fabric piece 15 passes by the photoelectric sensor 37,which detects the fabric piece 15 and signals the controller 17 of itspresence. If the fabric piece is destined for a receiving station 90connected to the main line 40a, the counterflow valve 36 remains closed;if instead the fabric piece 15 is destined for a receiving station 90connected with either of the main line 40b, 40c, the counterflow valve36 opens to enable a secondary air flow to urge the fabric piece 15 intothe proper main line without overshooting it. The ensuing discussionwill assume that an exemplary fabric piece 15 is destined for areceiving station 90 connected with a branch line 70 that is connectedwith T-fitting 48 on main line 40a; thus, the fabric piece 15 is totravel through the main line 40a, and the counterflow valve 36 remainsclosed.

After traveling through the manifold 35, the fabric piece 15 enters andbegins to travel downstream within the main line 40a. Once the fabricpiece 15 (or a sequential stream of fabric pieces 15 destined for acommon receiving tube 94) has passed the photoelectric sensor 43, thecontroller 17 signals the routing valve 42a to close to prepare for theunloading and transport of another fabric piece 15. Closing this valve42a ensures that the main line 40a will convey only one fabric piece 15(or a sequential stream of fabric pieces 15 destined for a commonreceiving tube 94) at a time to ensure that the piece 15 is transportedto the proper destination. Also, closing of the routing valve 42a freesthe fabric system 10 to convey another fabric piece 15 to a receivingstation 90 positioned on a different main line 40b, 40c and therebyincrease the throughput of fabric pieces 15.

In addition, detection of the fabric piece 15 by the photoelectricsensor 43 induces the controller 17 to open the supplementary air valve44 prior to the closing of the routing valve 42a. The opening of thisvalve 44 provides an air supply to convey the fabric piece 15 furtherthrough the main line 40a; otherwise, the closing of the routing valve42a would leave the main line 40a with no air supply with which toconvey the fabric piece 15.

The operation of the system 10 from this point depends on thepredetermined destination of the fabric piece 15. If, for example, thefabric piece 15 were to be conveyed to the receiving station 90 that isconnected with the branch line 70 attached to the T-fitting 46,detection of the fabric piece 15 by the photoelectric sensor 43 alsocauses the controller 17 to actuate the counterflow air valve 56. Ifinstead, and as assumed for exemplary purposes, the fabric piece 15 isto be conveyed to the receiving station 90 that is connected with thebranch line 70 attached to T-fitting 48, detection of the fabric piece15 by the photoelectric sensor 54 causes the controller 17 to actuatethe counterflow valve 56. Finally, if the fabric piece 15 were to beconveyed to a branch line 70 and receiving station 90 positioned fartherdownstream, the counterflow air valve 56 remains closed, and thecontroller 17 opens the counterflow valve 60.

Continuing with an exemplary fabric piece 15 that is to be conveyed intothe branch line 70 connected with the T-fitting 48, as the fabric piece15 approaches the T-fitting 48, it has a certain amount of downstreammomentum directed parallel to the main line 40a. Clearly, the fabricpiece 15 must overcome this momentum in order to be diverted into theproper branch line 70. To augment the suction provided by the vacuumsource 80 to the branch line 70, the opening of the counterflow valve 56provides a secondary air flow within the section of the main line 40abetween the counterflow valve 56 and the T-fitting 48 which flows in thedirection opposite that of the primary air flow (i.e., the airflowmoving downstream from the intake line 31 within the main line 40a). Asthe secondary air flow reaches the T-fitting 48, it is also divertedinto the branch line 70. As a result, as a fabric piece 15 nears andreaches the T-fitting 48, it is urged by the primary air flow and thesecondary airflow to pass into the branch line 70. Therefore, even ifthe fabric piece 15 has sufficient momentum from its travel through theupstream portion of the main line 40a that it "overshoots" the branchline 70 rather than being diverted, the fabric piece 15 is urged by thesecondary airstream to travel back to the branch line 70 and be conveyedtherethrough. This safeguard prevents fabric pieces 15 from simplylingering within the main line 40a in a position beyond the branch line70 and, in severe instances, from being misdirected to the incorrectdestination.

Further travel of the fabric piece 15 is best understood by reference toFIGS. 2 through 4. After the fabric piece 15 enters the desired branchline 70, it passes through the upstream conduit 72 and into the depositnozzle 74. As can be seen in FIG. 3, the airstream is drawn downwardlythrough the deposit nozzle 74, then upwardly within the lumen of thebifurcating section 76 and out the stem of the bifurcating section 76into the downstream conduit 78. From there the airstream is then drawnthrough the open vacuum valve 79, into the common vacuum lines 82, andto the vacuum source 80. In contrast, the fabric piece 15 has sufficientmomentum exiting the outlet end 75 of the deposit nozzle 74 that it isunable to reverse its direction (as the air flow does) and thus travelsdirectly into a predetermined receiving tube 94 of the receiving station90. As noted above, the deposit nozzle 74 is narrowed at its outlet end75 relative to its upstream end in order to accelerate the fabric piece15 exiting the outlet end 75 and thus provide additional momentum toprevent the fabric piece 15 from following the airstream.

Turning now to FIGS. 5 through 7, once the fabric piece 15 has beendeposited in a receiving tube 94 of the receiving station 90, thecontroller 17 may cause the carousel 92 to rotate about its axis (FIG.6) to a position in which another receiving tube 94' is positionedbeneath the outlet end 75 of the deposit nozzle 74. As such, it ispositioned to receive the next fabric piece conveyed through thatparticular branch line 70. Of course, rotation of the carousel 92depends on whether it is desired that the next fabric piece 15 bedeposited in the receiving tube 94 or the receiving tube 94'. In certainoperations, it may be preferred that all pieces that are to be used inthe same garment be deposited in the same receiving tube; in otheroperations, it may be preferred that similar fabric pieces for differentgarments be deposited in the same receiving tube.

It is noteworthy that the controller 17 monitors the location andultimate delivery of each fabric piece 15. As such, the operator neednot keep track of which fabric piece 15 is received in which receivingtube 94. As a result, parts for a single garment can be conveyed tomultiple receiving stations 90 without losing garment associativity asthe unassembled pieces 15 progress from one sewing operation to thenext.

Once the fabric piece 15 (or the final fabric piece 15 of a sequentialstream of fabric pieces destined for a common receiving tube 94) hasreached the receiving tube 94, the vacuum valve 79 and the supplementaryair valve 44 are directed by the controller 17 to close. This actiondiscontinues the suction within the main line 40a and the branch line70. As such, the main line 40a is then ready to receive another fabricpiece 15 to be conveyed to the same or to another destination.

As can be discerned from the foregoing discussion and the accompanyingdrawings, the fabric transport system 10 can quickly and easily conveyfabric pieces to diverse destinations. Back-up mechanisms, such as therouting valves 42a, 42b, 42c, the counterflow valves 56 and 60, and thenarrowed end 75 of the deposit nozzle 74 vastly reduce or eliminateincomplete or incorrect delivery of fabric pieces. The fabric transportsystem 10 can operate with virtually no labor. As such, it cancomfortably be integrated into the aforementioned APPAREL ON DEMANDclothing production concept.

Those skilled in this art will recognize that the present invention mayinclude alternative configurations for unloading and initial transport.For example, if only two main lines are to be employed, each can beconnected to the suction head 24 through its own intake line. Thepincher 25 can be designed to alternatively place fabric pieces in oneintake line, then the other, for transport to their respective mainlines. Such a configuration would not need to include a common manifoldfrom which the main lines extend.

The foregoing embodiments is illustrative of the present invention, andare not to be construed as limiting thereof. The invention is defined bythe following claims, with equivalents of the claims to be includedtherein.

That which is claimed is:
 1. A system for transporting a fabric piecefrom a predetermined departure location to a first predetermineddestination, said system comprising a series of fluidly communicatingtubes and including:an intake line configured to receive a fabric piecefrom the predetermined departure location; a main line having first andsecond ends and being fluidly connected at said first end with saidintake line; a first branch line having upstream and downstream endsfluidly connected at said upstream end to an intermediate portion ofsaid main line at a first junction, said first branch line including adeposit nozzle leading to the first predetermined destination; a vacuumsource connected with said downstream end of said first branch line fordrawing air of sufficient quantity and velocity through said intakeline, said main line, and said first branch line to draw a fabric pieceinto said intake line and said main line; a counterflow valve positionedon an intermediate portion of said main line between said first junctionand said main line second end, said counterflow valve being configuredto take open and closed positions; and means for actuating saidcounterflow valve to take its open position prior to a fabric piecepassing said first junction such that air is drawn into said main lineand subsequently into said first branch line by said vacuum source so asto assist a fabric piece traveling in said main line from said intakeline to be shunted into said first branch line from said main line. 2.The fabric transport system defined in claim 1, further comprising avalve positioned on said first branch line downstream of said depositnozzle, said valve being moveable between an open position in which airis free to be drawn through said first branch line to said vacuumsource, and a closed position in which air is prevented from being drawnthrough said first branch line to said vacuum source.
 3. The fabrictransport system defined in claim 1, further comprising a second branchline interconnected at one end with said main line and at an oppositeend to said vacuum source, said second branch line further including asecond deposit nozzle leading to a second predetermined destination. 4.The fabric transport system defined in claim 3, further comprising asecond valve positioned on said second branch line downstream of saidsecond deposit nozzle, said second valve being moveable between an openposition, in which air is free to be drawn through said second branchline to said vacuum source, and a closed position, in which air isprevented from being drawn through said second branch line to saidvacuum source.
 5. The fabric transport system defined in claim 1,further comprising a receiving station positioned downstream of saidfirst branch line deposit nozzle at the first predetermined destination.6. The fabric transport system defined in claim 5, wherein saidreceiving station comprises:a plurality of receptacles; and means formoving at least one of said plurality of receptacles into a positionadjacent an outlet end of said deposit nozzle to receive the fabricpiece.
 7. The fabric transport system defined in claim 6, wherein saidreceiving station further comprises fabric piece exit means forwithdrawing the fabric piece from said receiving station.
 8. The fabrictransport system defined in claim 7, wherein said fabric piece exitmeans comprises a door moveable between an open position, in which thefabric piece is accessible for removal, and a closed position, in whichthe fabric piece is inaccessible for removal.
 9. The fabric transportsystem defined in claim 1, further comprising a fabric cutting tablehaving an unloading surface, and wherein the predetermined departurelocation is located upon said unloading surface.
 10. The fabrictransport system defined in claim 9, wherein said intake line isoperably coupled with means for moving said intake line to thepredetermined departure location.
 11. The fabric transport systemdefined in claim 1, wherein said deposit nozzle includes a narroweddownstream end.
 12. A system for providing a cut fabric piece to a firstpredetermined destination, said system comprising:a fabric cutting tablefor supporting a fabric piece; means for cutting a fabric piece into oneor more fabric pieces; means for supporting said fabric pieces inrespective departure positions; a series of fluidly communicating tubesand including:an intake line configured to receive a fabric piece fromthe predetermined departure location; a main line having first andsecond ends and being fluidly connected at said first end with saidintake line; a first branch line having upstream and downstream endsfluidly connected at said first end to an intermediate portion of saidmain line at a first junction, said first branch line having a depositnozzle leading to the first predetermined destination; a vacuum sourceconnected with said downstream end of said first branch line for drawingair of sufficient quantity and velocity through said intake line, saidmain line, and said first branch line to draw a fabric piece into saidintake line and said main line; a counterflow valve positioned on anintermediate portion of said main line between said first junction andsaid main line second end, said counterflow valve being configured totake open and closed positions; and means for actuating said counterflowvalve to take its open position prior to a fabric piece passing saidfirst junction such that air is drawn into said main line andsubsequently into said first branch line by said vacuum source so as toassist a fabric piece traveling in said main line from said intake lineto be shunted into said first branch line from said main line; and areceiving station at the first predetermined destination.
 13. The fabrictransport system defined in claim 12, further comprising a valvepositioned on said first branch line downstream of said deposit nozzle,said valve being moveable between an open position in which air is freeto be drawn through said first branch line to said vacuum source, and aclosed position in which air is prevented from being drawn through saidfirst branch line to said vacuum source.
 14. The fabric transport systemdefined in claim 13, further comprising a second branch lineinterconnected at one end with said main line and at an opposite end tosaid vacuum source, said second branch line further including a seconddeposit nozzle leading to a second predetermined destination.
 15. Thefabric transport system defined in claim 14, further comprising a secondvalve positioned on said second branch line downstream of said seconddeposit nozzle, said second valve being moveable between an openposition, in which air is free to be drawn through said second branchline to said vacuum source, and a closed position, in which air isprevented from being drawn through said second branch line to saidvacuum source.
 16. The fabric transport system defined in claim 12,further comprising a receiving station positioned downstream of saidfirst branch line deposit nozzle at the first predetermined destination.17. The fabric transport system defined in claim 16, wherein saidreceiving station comprises:a plurality of receptacles; and means formoving at least one of said plurality of receptacles into a positiondownstream of said deposit nozzle to receive the fabric piece.
 18. Thefabric transport system defined in claim 17, wherein said receivingstation further comprises fabric piece exit means for withdrawing thefabric piece from said receiving station.
 19. The fabric transportsystem defined in claim 18, wherein said fabric piece exit meanscomprises a door moveable between an open position, in which the fabricpiece is accessible for removal, and a closed position, in which thefabric piece is inaccessible for removal.
 20. The fabric transportsystem defined in claim 12, further comprising a fabric cutting tablehaving an unloading surface, and wherein the predetermined departurelocation is located upon said unloading surface.
 21. The fabrictransport system defined in claim 20, wherein said intake line isoperably coupled with means for moving said intake line to thepredetermined departure location.
 22. The fabric transport systemdefined in claim 12, wherein said deposit nozzle includes a narroweddownstream end portion.
 23. A method of transporting a fabric piece froma departure station to a first predetermined destination, said methodcomprising the steps of:passing a first airstream through an inlet andinto a main tube, said airstream having sufficient velocity andvolumetric flow to lift the fabric piece from the departure station andconvey it into the main tube; passing the first airstream from the maintube through a first branch tube to convey the fabric piece from themain tube into the first branch tube; opening a valve positioned on themain tube downstream of the first branch tube so that a second airstreampasses through the valve, into the main tube, and into the first branchtube, said opening step being performed prior to the fabric pieceentering the first branch tube, said second airstream being ofsufficient velocity and volumetric flow to urge the fabric piece toenter the first branch tube; passing the first and second airstreamtoward the first predetermined destination so that the fabric piece isconveyed thereto.